Heat-not-burn device and method

ABSTRACT

A device and method for converting a consumable into an aerosol with high heat without burning the consumable by packaging the consumable containing an internal susceptor inside a housing. A first end of the housing can be capped with an end cap and a second end of the housing can have a mouthpiece. The housing containing the consumable and the susceptor can be placed inside a case with an inductive heating element configured to heat the susceptor. Heating the susceptor results in the consumable being released as an aerosol for inhalation.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is a continuation of U.S. application Ser. No.17/001,348, filed Aug. 24, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/022,482, filed Jun. 28, 2018, which claims thebenefit of U.S. Provisional Patent Application Ser. No. 62/613,355,entitled “METHODS OF CONFORMING AND COATING A SUSCEPTOR TO EFFICIENTLYHEAT TOBACCO VIA AN INDUCTIVE PROCESS,” filed Jan. 3, 2018, whichapplications are incorporated in their entirety here by this reference.

TECHNICAL FIELD

This invention relates to devices used as alternatives to conventionalsmoking products, such as electronic cigarettes, vaping systems, and inparticular, heat-not-burn devices.

BACKGROUND

Heat-not-burn (HNB) devices heat tobacco at temperatures lower thanthose that cause combustion to create an inhalable aerosol containingnicotine and other tobacco constituents, which is then made available tothe device's user. Unlike traditional cigarettes, the goal is not toburn the tobacco, but rather to heat the tobacco sufficiently to releasethe nicotine and other constituents through the production of aerosol.Igniting and burning the cigarette creates unwanted toxins that can beavoided using the HNB device, However, there is a fine balance betweenproviding sufficient heat to effectively release the tobaccoconstituents in aerosol form and not burn or ignite the tobacco. CurrentHNB devices have not found that balance, either heating the tobacco attemperatures that produce an inadequate amount of aerosol or overheating the tobacco and producing an unpleasant or “burnt” flavorprofile. Additionally, the current methodology leaves traditional HNBdevice internal components dirtied with burning tobacco byproducts andthe byproducts of accidental combustion.

For the foregoing reasons there is a need for an aerosol producingdevice that provides its user the ability to control the power of thedevice, which will affect the temperature at which the tobacco will beheated via the inductive method to reduce the risk of combustion—even atwhat would otherwise be sufficient temperatures to ignite—whileincreasing the efficiency and flavor profile of the aerosol produced.

SUMMARY

The present invention is directed to a system and method by which aconsumable tobacco component is quickly and incrementally heated byinduction, so that it produces an aerosol that contains certain of itsconstituents but, not with the byproducts most often associated withcombustion, for example, smoke, ash, tar and certain other potentiallyharmful chemicals. This invention involves positioning and incrementallyadvancing heat along consumable tobacco component with the use of aninduction heating element that provides an alternating electro-magneticfield around the component.

An object of the present invention is a device wherein an inductionheating source is provided for use to heat a consumable tobaccocomponent.

Another object of the present invention is a consumable tobaccocomponent comprised of several, sealed, individual, airtight, coatedencasements containing a consumable tobacco preparation—and an inductionheating source. The encasement may be an aluminum shell with pre-setopenings. The encasements may be coated with a gel that seals theopenings until an inductive heating process melts the gel, clearing theopenings. In some embodiments, the gel can include a flavoring agentthat can add flavor to or enhance the flavor of the tobacco aerosol.

In some embodiments, multiple encasements are stacked inside a papertube with spaces between them, formed by excess aluminum wrapping at thebottom end of each encasement and channels on either side to allow forthe aerosol produced. When the inductive heating source is activated,the pre-set openings are cleared, and flavor is combined with theaerosol to travel through the tube and be made available to the user ofthe device.

Using these methods and apparatus, the device is required to heat lessmass, can heat-up immediately, cool down quickly and conserve power,allowing for greater use between re-charging sessions. This contrastswith the well-know current, commercially available heat-not-burndevices.

Another object of the present invention is a tobacco-containingconsumable component comprised of several, sealed, individual, airtight,coated encasements and an induction heating source. The encasements arethen coated with a gel that seals them until an inductive heatingprocess can melt the gel, clearing the openings. In some embodiments,the gel can include a flavoring agent that can add flavor to or enhancethe flavor of the consumable tobacco component.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a side view inside of an embodiment of the presentinvention

FIG. 2A shows a perspective view of an embodiment of the presentinvention with portions removed to show inside the embodiment.

FIG. 2B shows a perspective view of the embodiment shown in FIG. 2A withportions cut away and/or removed to reveal internal components.

FIG. 2C shows a cross-sectional view of the embodiment shown in FIG. 2Acut along line 2C-2C.

FIG. 2D shows an exploded view of the embodiment shown in FIG. 2A.

FIG. 2E shows a perspective view of another embodiment of the presentinvention with portions cut away and/or removed to reveal internalcomponents.

FIG. 3A shows a perspective view of another embodiment of the presentinvention.

FIG. 3B shows a partially exploded view of the embodiment shown in FIG.3A.

FIG. 3C shows a perspective view of the embodiment shown in FIG. 3A withportions cut away and/or removed to reveal internal components.

FIG. 3D shows a close-up, perspective view of a consumable-containingunit shown in FIG. 3A.

FIGS. 4A and 4B show an exploded views of embodiments of aconsumable-containing unit.

FIG. 5A shows a perspective view of another embodiment of the presentinvention.

FIG. 5B shows a cross-sectional view of the embodiment shown in FIG. 5Ataken along line 5B-5B.

FIG. 5C shows a perspective view of a consumable-containing package fromthe embodiment shown in FIG. 5A.

FIG. 6A shows a perspective view of another embodiment of the presentinvention.

FIG. 6B shows an exploded view of the embodiment shown in FIG. 6A.

FIGS. 7A and 7B show perspective views of other embodiments of thepresent invention.

FIG. 8A shows a side view of an embodiment of the heating element.

FIG. 8B shows a front of the heating element shown in FIG. 7A.

FIG. 7C shows another embodiment of the present invention.

FIG. 7D shows an exploded view of the embodiment in FIG. 7C.

FIG. 9A shows a side view of an embodiment of the aerosol producingdevice.

FIG. 9B shows a top view of the aerosol producing device shown in FIG.8A.

FIG. 9C shows a schematic diagram of an embodiment of the controller andits connection to other components of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in con on with the appendeddrawings is intended as a description of presently-preferred embodimentsof the invention and is not intended to represent the only forms inwhich the present invention may be constructed or utilized. Thedescription sets forth the functions and the sequence of steps forconstructing and operating the invention in connection with theillustrated embodiments. It is to be understood, however, that the saneor equivalent functions and sequences may be accomplished by differentembodiments that are also intended to be encompassed within the spiritand scope of the invention.

The invention of the present application is a device for generatingaerosols from a consumable-containing product for inhalation in a mannerthat utilizes relatively high heat with minimal burning of theconsumable-containing product. For the purposes of this application, theterm “consumable” is to be interpreted broadly to encompass any type ofpharmaceutical agent, drug, chemical compound, active agent,constituent, and the like, regardless of whether the consumable is usedto treat a condition or disease, is for nutrition, is a supplement, orused for recreation. By way of example only, a consumable can includepharmaceuticals, nutritional supplements, over-the-counter medicants,tobacco, cannabis, and the like.

With reference to FIG. 1 , the device 100 comprises aconsumable-containing package 102 and an aerosol producing device 200.The device 100 generates aerosols through a heat-not-burn process inwhich a consumable-containing unit 104 is heated to a temperature thatdoes not burn the consumable-containing unit 104, but does release theconsumable from the consumable-containing unit the form of an aerosolproduct that can be inhaled. Thus, a consumable-containing unit 104 isany product that contains a consumable that can be released into aerosolform when heated to the proper temperature. The present applicationdiscusses application of the invention to a tobacco product to provide aconcrete example. The invention, however, is not limited to use withtobacco products.

Consumable-Containing Package

With reference to FIGS. 2A-6B, the consumable-containing package 102 isthe component that is heated to release the consumable in aerosol form.The consumable-containing package 102 comprises a consumable-containingunit 104, a metal (also referred to as the susceptor) 106 for heatingthe consumable-containing unit 104 through an inductive heating system,and an encasement 108 to contain the consumable-containing unit 104 andthe susceptor 106. How well the consumable-containing package 102 isheated is dependent on product consistency. Product consistency takesinto consideration various factors, such as the position, shape,orientation, composition, and other characteristics of theconsumable-containing unit 104. Other characteristics of theconsumable-containing unit 104 may include the amount of oxygencontained in the unit. The goal is to maximize product consistency bykeeping each of these factors consistent in the manufacturing process.

If the form of the consumable-containing unit 104 is in direct physicalcontact with the susceptor 106 with maximal contact area between each,then it can be inferred that the thermal energy induced in the susceptor106 will be largely transferred to the consumable-containing unit 104.As such, the shape and arrangement of the consumable-containing unit 104relative to the susceptor 106 is an important factor. In someembodiments, the consumable-containing unit 104 is generally cylindricalin shape. As such, the consumable-containing unit 104 may have acircular or oval-shaped cross-section.

In addition, another objective with respect to the design of theconsumable-containing unit 104 is to minimize the amount of air to whichthe consumable-containing unit 104 is exposed. This eliminates ormitigates the risk of oxidation or combustion during storage or duringthe heating process. As a result, at certain settings, it is possible toheat the consumable-containing unit 104 to temperatures that wouldotherwise cause combustion when used with prior art devices that allowmore air exposure.

As such, in the preferred embodiment, the consumable-containing unit 104is made from a powdered form of the consumable that is compressed into apellet or rod. Compression of the consumable reduces the oxygen trappedinside the consumable-containing unit 104. In some embodiments, theconsumable-containing unit 104 may further comprise an additive, such asa humectant, flavorant, filler to displace oxygen, or vapor-generatingsubstance, and the like. The additive may further assist with theabsorption and transfer of the thermal energy as well as eliminating theoxygen from the consumable-containing unit 104. In an alternativeembodiment, the consumable may be mixed with a substance that does notinterfere with the function of the device, but displaces air in theinterstitial spaces of the consumable and/or surrounds the consumable toisolate it from the air. In yet another alternative embodiment, theconsumable could be formed into tiny pellets or other form that can beencapsulated to further reduce the air available to the consumable.

As shown in FIGS. 2A-2D, in the preferred embodiment, theconsumable-containing unit 104 may be one elongated unit defining alongitudinal axis L. For example, the consumable-containing unit 104 maybe an elongated cylinder or tube having a circular transversecross-section or an oval transverse cross-section. As such, theconsumable-containing unit 104 may be defined by two opposing ends 105,107 and a sidewall 109 therebetween extending from the first end 105 tothe second end 107 defining the length of the consumable-containing unit104.

The susceptor 106 may be similarly elongated and embedded in theconsumable-containing unit 104, preferably, along the longitudinal axisL and extending substantially the length and width (i.e. the diameter)of the consumable-containing unit 104. In consumable-containing units104 having an oval cross-section, the diameter refers to the majordiameter defining the long axis of the oval.

The susceptor 106 can be machine extruded. Once extruded, theconsumable-containing unit 104 can be compressed around the susceptor106 along the length of the susceptor 106. Alternatively, the susceptor106 could be stamped from flat metal stock or any other suitable methodof fabrication prior to assembling the consumable containing 104 aroundthe susceptor 106. In some embodiments, as shown in FIG. 2E, thesusceptor 106 may be made of steel wool. For example, the susceptor 106may be comprised of fine filaments of steel wool bundled together in theform of a pad. As such, the steel wool pad comprises numerous fineedges. In some embodiments, the steel wool pad may be doused with,immersed in, or fully filled with the additive, such as a humectant,flavorant, vapor-generating substance, a substance to retard oxidationof the steel wool (rust), and/or a filler to eliminate air between thesteel wool filaments, and the like. As shown FIG. 2E, there may becut-outs along the steel wool pad to divide the consumable containingunit 104 into discrete segments for individual heating, as describedbelow. Alternatively, individual pads of steel wool may be used,separated by space and/or consumable, so that each pad may be heatedindividually during use.

Advantages of the steel wool, include, but are not limited to, easydisposability from an environmental standpoint in that it begins tooxidize soon after it is heated; and thereby, becomes friable anddegrades easily without dangerous sharp edges. Being composed of ironand carbon it is relatively non-toxic.

The susceptor 106 can be made of any metal material that generates heatwhen exposed to varying magnetic fields as in the case of inductionheating. Preferably, the metal comprises a ferrous metal. To maximizeefficient heating of the consumable-containing unit 104, the susceptor106 generally matches the shape of the largest cross-sectional area ofthe consumable-containing unit 104 so as to maximize the surface areawith which the consumable-containing unit 104 comes into contact withthe susceptor 106, but other configurations may also be used. In theembodiments in which the consumable-containing unit 104 is an elongatedcylinder, the largest cross-sectional area would be defined by dividingthe elongated cylinder down the longitudinal axis L along its majordiameter creating a rectangular cross-sectional area. As such, thesusceptor 106 would also be rectangular with dimensions substantiallysimilar to the dimensions of the cross-sectional area of the elongatedcylinder.

In some embodiments, the susceptor 106 may be a metal plate. In someembodiments, the susceptor 106 may be a metal plate with a plurality ofopenings 110, like a mesh screen. Inductive heating appears to be mosteffective and efficient at the edges of the susceptor 106. A mesh screencreates more edges in the susceptor 106 that can contact theconsumable-containing unit 104 because the edges define the openings110.

Preferably, the susceptor 106 may be a strip patterned with an array ofsmall openings 110 to increase the amount of edges that can be utilizedin an efficient inductive heating process, followed by a larger gap 112that allows for that length of the susceptor 106 that will not allow forinductive heating, or at least mitigate inductive heating and/ormitigate conduction from the segment being heated. This configurationallows for the consumable-containing package 102 to be heated indiscrete segments. The elongated susceptor 106 may be an elongated metalplate having a longitudinal direction, the elongated metal platecomprising sets of openings 110 a, 110 b and sets of gaps 112 a, 112 bwherein the sets of openings 110 a, 110 b alternate in series with thesets of gaps 112 a, 112 b along the longitudinal direction of theelongated metal plate such that each set of openings 110 a, 110 b isadjacent to one of the gaps 112 a, 112 b. Therefore, moving from one endof the susceptor 106 to the opposite end, there is a first set ofopenings 110 a, then a first gap 112 a, then a second set of openings110 b, then a second gap 112 b, and so on. In the area of the gaps 112,there is very little metal material; therefore, there is minimal heattransfer. As such, even though the consumable-containing unit 104 is asingle unit, it can still be heated in discrete sections. Theconsumable-containing unit 104 and susceptor 106 are then wrapped in anencasement 108.

In the preferred embodiment, the encasement 108 may be made of aluminumwith pre-punched openings 120. The consumable-containing unit 104 isplaced inside the encasement 108 to contain the heat generated by thesusceptor 106. The openings 120 in the encasement 108 allow theconsumable aerosol to escape when heated. Because the openings 120create an avenue through which air can enter into the encasement 108 tobe exposed to the consumable-containing unit 104, the openings 120 maybe temporarily sealed using a coating. The coating is preferably made ofa composition that melts at temperatures that create consumableaerosols. Therefore, as the susceptor 106 is heated, due to the lack ofair inside the encasement 108, the consumable-containing unit 104 can beraised to exceedingly high temperatures without combusting. As thesusceptor 106 reaches high temperatures, the consumable aerosols thatbegin to form, are not able to escape. When the coating melts away andexposes the opening 120, then the consumable aerosols are able to escapethe encasement 108 for inhalation. In the preferred embodiment, thecoating may be propylene glycol alginate (“PGA”) gel. The coating mayalso include a flavoring. Therefore, as the coating melts away and theconsumable aerosol is released, the flavoring is also released with theconsumable aerosol. In some embodiments, the flavoring can be mixed withthe additive.

In some embodiments, the openings 120 may be a plurality of holes orslits. The openings 120 may be formed along the length of the sidewall122 of the encasement 108, arranged radially around the sidewall 122,arranged randomly or uniformly throughout the sidewall 122, and thelike. In some embodiments, the openings 120 may be a plurality of holesalong the opposite ends 124, 126 of the encasement 108. In someembodiments with the elongated consumable-containing unit 104, theencasement 108 may also be elongated with the opening 120 in the form ofone or more elongated slits traversing the length of the encasementparallel to the longitudinal axis L, thereby creating a seam. That seammay be folded or crimped, but still leave a gap through which consumableaerosols may travel, either along its entire length or in discreteareas. Like the openings 120 described above, the seam may be sealedwith a coating.

The consumable-containing package 102 may further comprise a filter tube140 to encapsulate the consumable-containing unit 104, susceptor 106,and the encasement 108. The filter tube 140 may be made of tiltermaterial to capture any unwanted debris while allowing the consumableaerosol that is released from the heating of the encasement to passtransversely through the filter. The filter tube 140 may surround theencasement 108 and further cover the coated openings 120. Because thefilter tube 140 may be made of filtering material, the consumableaerosol is able to travel through the filter tube 140. By way of exampleonly, the filter tube may be made of cellulose or cellulose acetate,although any suitable filter material may be used.

The consumable-containing package 102 may further comprise a housing 150to enclose the filter tube 140. The housing 150 may be a paper tube. Thehousing 150 is less likely to allow the consumable aerosols to passthrough. As such, the housing 150 wrapped around the filter tube 140creates a longitudinal channel through the filter tube 140 through whichthe consumable aerosol travels, rather than escaping radially out thefilter tube 140. This allows the consumable aerosol to follow the pathof inhalation towards the user's mouth. One end 152 of the housing 150may be capped with an end cap 154. The end cap 154 may be comprised of atype of filter material. At the opposite end 156 of the housing 150 is amouthpiece 158 that the user sucks on to draw the heated consumableaerosol out of the encasement 108 along the filter tube 140 towards themouthpiece 158 and into the user's mouth. As such, the mouthpiece 158may also be a type of filter, similar to that of the end cap 154. Wherethe consumable containing package 102 includes a channel through whichthe consumable aerosol travels, and that channel leads directly to themouthpiece 158 that is also part of the consumable containing package102, and the channel is isolated from the case 202, the case 202 willremain free of any residue or byproducts formed during operation of thedevice. In this configuration, the case 202 stays clean and does notrequire the user to periodically clean out the case 202.

In some embodiments, the encasements 108 may be made of a two piece unithaving a first encasement section 108 a and a second encasement section108 b. The consumable-containing unit 104 can be inserted into the firstencasement section 108 a and the second encasement section 108 b may beplaced on top of the first encasement section 108 a to cover theconsumable-containing unit 104. Preset openings 120 can be formed intothe encasement 108 prior to encapsulating the consumable-containing unit104.

Having established the general principles of the consumable-containingpackage 102, variations have also been contemplated that achieve thesame objectives. For example, in some embodiments, theconsumable-containing unit 104 may comprise two elongated sections 104a, 104 b. The two elongated sections 104 a, 104 b of theconsumable-containing unit 104 may be defined by a plane parallel to andcutting through the longitudinal axis L along the diameter. Therefore,the two elongated sections 104 a, 104 b may be half-cylinder sectionsthat when mated together form a full cylindrical consumable-containingunit 104.

In some embodiments, as shown in FIGS. 3A-3D, the consumable-containingunit 104 may be in the form of pellet or tablet. Unlike theconsumable-containing unit 104 that is an elongated cylinder or tube inwhich the length of the sidewall 109 is much longer than the diameter,in the tablet embodiment, the tablet may be a short cylinder defining alongitudinal axis L, wherein length of the sides sidewall 109 is closerto the size of the diameter, or shorter than the diameter. The susceptor106 may hive a flat, circular shape to match the cross-sectional shapeof the tablet when cut transversely, perpendicular to the longitudinalaxis L. The consumable-containing unit 104 can be compressed about thesusceptor 106. To mimic a cigarette, a plurality of theconsumable-containing units 104 can be stacked, end-to-end along theirlongitudinal axes L, to form an elongated cylinder. Therefore, eachindividual consumable-containing unit 104 can be heated separately,effectively mimicking the segments of the consumable-containing unit 104having an elongated, tubular body.

Other shapes can also be used, such as square or rectangular with asusceptor 106 having a corresponding shape. The cylindrical shape,however, is preferred because of the ease with which such shape can beused to mimic the shape of an actual cigarette.

In some embodiments, the consumable-containing unit 104 may be formedfrom two sections 104 a, 104 b of the consumable-containing unit 104combined together to make a whole, as shown FIGS. 4A and 4B. The twosections 104 a, 104 b are defined by splitting the consumable-containingunit 104 in half transversely along a plane perpendicular to thelongitudinal axis L. The susceptor 106 may be sandwiched in between thetwo sections 104 a, 104 b. With the susceptor 106 sandwiched in betweenthe two consumable-containing sections 104 a, 104 b, theconsumable-containing unit 104 can be enclosed by the encasement 108.This process can be repeated to create a plurality of individualconsumable-containing units 104 sandwiching respective susceptors 106,each individually contained in a respective encasement 108. Theplurality of consumable-containing units 104 may be stacked, one on topof the other to create the consumable-containing package 102 in whicheach individual consumable-containing unit 104 may be heatedindividually, one at a time.

In some embodiments, the encasement 108 may be aluminum wrapped around aconsumable-containing unit 104. The aluminum can have excess folds 130,132 at opposite ends as shown in FIG. 3D). These excess folds 130, 132create a gap in between adjacent consumable-containing units 104 whenstacked on top of each other.

In some embodiments, the encasement 108 may be two-pieces having a firstencasement section 108 a and a second encasement section 108 b thatserves as a covering or cap to enclose the consumable-containing unit104 inside the first encasement section 108 a, as shown in FIGS. 4A and4B. As described previously, the openings 120 on the encasement 108 maybe along the sidewall 122 or at the ends 124, 126. As describedpreviously, the susceptor 106 may be any type of metal that is subjectto induced heating, including steel wool as shown FIG. 4B. In thepreferred embodiments, numerous edges are created in the susceptor 106by creating a plurality of holes 110 or using steel wool filamentscompressed together. The steel wool filaments may be fine to mediumgrade. As discussed above, the steel wool pad may be soaked in, coated,or filled with additive, flavorant, protectant, and/or filler.

In some embodiments, a plurality of consumable-containing units 104 maybe contained in a single elongated encasement 108, as shown in FIGS.5A-6B. The encasement 108 may be molded with compartments 111 to receiveeach individual consumable-containing unit 104. In some embodiments, theindividual compartments 111 may be connected to each other by a bridge121. In some embodiments, the bridge 121 may define a channel 125 thatallows fluid communication from one compartment 111 to another. In someembodiments, the bridge 121 may be crimped to prevent fluidcommunication between one compartment 111 and the other through thebridge 121. In some embodiments, the elongated encasement 108 may be atwo-piece assembly split transversely along the longitudinal axis L, asshown in FIGS. 6A-6B. The consumable-containing units 104 can be seatedin the compartments 111 of one of the encasement sections 108 a. Thesecond encasement section 108 b can then be mated to the firstencasement section 108 a to cover the consumable-containing units 104,The split between the first encasement section 108 a and the secondencasement section 108 b can be used as the opening 120. Alternatively,preset openings 120 can be formed in one or both of the encasementsections 108 a, 108 b.

In some embodiments, as shown in FIG. 7A-7D, the encasement 108 may bemade out of material that allows the encasement 108 to serve as thesusceptor. For example, the encasement 108 can be made of steel, orotherwise comprise ferrous metal, or any other metal that can be heatedusing induction heating. In such an embodiment, an interior susceptor106 would not be required to be embedded into the consumable-containingunit 104. The encasement 108 can still comprise a plurality of holes120, and be covered with an additive and/or sealant such as PGA. Such anembodiment can be made into an elongated tube as shown in FIG. 7A orinto tablets or disks as shown in FIG. 7B. The encasement 108 can be atwo piece encasement having a first encasement section 108 a and asecond encasement section 108 b as discussed previously.

In some embodiments, the encasement 108 may have transverse slits 123transversely across the encasement 108, generally perpendicular to thelongitudinal axis L as shown in FIGS. 7C and 7D. The slits 123 createsegmentation in the encasement 108 so that only a small segment of theconsumable-containing unit 104 is heated per actuation. The transverseslits 123 may be through holes, which expose the consumable-containingunit 104 underneath. In such embodiments, the segments may be filledwith a coating or some other plug to seal the hole, either permanentlyor with a substance that will melt upon heating and allow the aerosol toescape through the slit 123. In some embodiments, the plug may be madefrom material that can function as a heat sink and/or a substance thatis not easily heated via induction to reduce the heating effect at thetransverse slits 123. In some embodiments, the transverse slit 123 maybe a recessed portion of or an indentation in the encasement 108. Inother words, the transverse slit 123 may be a thinned portion of theencasement 108. As such, the transverse slit 123 may define a well. Thewell can be filled with a plug that can function as a heat sink and/or asubstance that is not easily heated via induction to reduce the heattransfer along the transverse slit 123.

Induction Heating

Heating the consumable-containing unit 104 is achieved by an inductionheating process that provides non-contact heating of a metal, preferablyferrous metal, by placing the metal in the presence of a varyingmagnetic field generated by an inductive heating element 160, as shownin FIGS. 8A-8B. In the preferred embodiment, inductive heating element160 is a conductor 162 wrapped around into a coil that generates themagnetic field when current is passed through the coil. The metalsusceptor 106 is placed close enough to the conductor 162 so as to bewithin the magnetic field. In the preferred embodiment, the coil iswrapped in a manner that defines a central cavity 164. This allows theconsumable-containing package 102 to be inserted into the cavity 164 tohave the coil surround the susceptor 106 without touching the susceptor106. The current passed through the coil is alternating current creatinga rapidly alternating magnetic field. The alternating magnetic field maycreate eddy currents in the susceptor 106, which may generate heatwithin the susceptor 106. Thus the consumable-containing package 102 isgeneral heated from the inside out. In embodiments in which theencasement 108 also serves as the susceptor, the consumable-containingpackage 102 is heated from the outside in.

In the preferred embodiment, segments of the consumable-containingpackage 102 are to be heated individually. As such, the conductor 162may also be provided as individual sets of coiled conductors 162 a-f, asshown in FIG. 8A. Each conductor coil 162 a-f may be attached to acontroller 166 that can be controlled to activate one conductor coil 162a-f at a time. Although there are six (6) conductor coils 162 a-f shownin FIG. 8A, greater or fewer coils could be used. In an alternativeembodiment, a single conductor coil 162 may be used, with a mechanicalmechanism that translates the coil along the consumable-containingpackage 102 to individually heat each segment of theconsumable-containing package 102.

The individual conductor coils 162 a-f may match up with discretesegments of the consumable-containing package 102, as described above,and shown in FIGS. 3A-6B. Alternatively, the conductor coils 162 a-fcould each correspond to a certain length of a continuousconsumable-containing package 102 such as shown in FIGS. 2A-2D, 7A, and7D, to heat only that certain length. In preliminary testing of suchembodiments, heating along discrete lengths of the consumable-containingpackage 102 does not appreciably heat adjacent portions of theconsumable-containing package 102, as the adjacent non-heated consumableappears to act as an insulator. Thus, structures to limit heat transfermay not be necessary, although such structures have been discussedherein and may be useful.

The efficiency of conversion of electric power into thermal heat in thesusceptor 106 is referred to herein as the “conversion efficiency,” andis based on a variety of factors, such as bulk resistivity of the metal,dielectric of the metal, metal geometry and heat loss, power supplyconsistency and efficiency, coil geometry, and losses and overallfrequency of operation—to identify some of these factors. The device 100is designed d configured to maximize the conversion efficiency.

Aerosol Producing Device

To effectuate the heating and conversion to an aerosol of theconsumable, the housing 150 containing the filter tube 140 wrappedaround the consumable-containing unit 104 is placed inside an aerosolproducing device 200, as shown in FIGS. 9A-9C. The aerosol producingdevice 200 comprises a case 202 to contain the consumable-containingpackage 102, the induction heating element 160 to heat the susceptor106, and a controller 166 to control the induction heating element 160.

The case 202 is designed for ergonomic apse. For ease of nomenclature,the case 202 is described using terms such as front, back, sides, topand bottom. These terms are not meant to be limiting, but rather, usedto describe the positions of various components relative to each other.For purposes of describing the present invention, the front 210 will bethe portion of the case 202 that faces the user when used as intended asdescribed herein. As intended, when the user grasps the case 202 foruse, the fingers of the user will wrap around the back 212 of the device100 with the thumb wrapping around the front 210.

The case 202 defines a cavity 214 (see FIG. 1 ) in which the componentsof the device 100 are contained. As such, the case 202 is designed tocontain a substantial portion of the consumable-containing package 102,the controller 166, the inductive heating element 160, and the powersource 220. In the preferred embodiment, the top-front portion of thecase 202 defines an orifice 216. The mouthpiece portion 158 of theconsumable-containing package 102 projects out from the orifice 216 sothat the user has access to the consumable-containing package 102. Themouthpiece 158 projects sufficiently out of the case 202 to allow theuser to place his or her lips around the mouthpiece 158 to inhale theconsumable aerosol.

The case 202 is intended to be user-friendly and easily carried. In thepreferred embodiment, the case 202 may have dimensions of approximately85 mm tall (measured from top 222 to bottom 224) by 44 mm deep (measuredfrom front 210 to back 212) by 22 mm wide (measured from side 226 toside 228). This may be manufactured by proto-molding for higherquality/sturdier plastic parts.

In some embodiments, the consumable-containing package 102 may be heldin a retractor that allows the consumable-containing package 102 to beretracted inside the case 202 for storage and travel. Due to theconfiguration of the consumable-containing package 102, the case 202does not need a clean-out through-hole like other devices in which somecombustion is still prevalent creating byproduct residue from thecombustion. In embodiments where the consumable-containing package 102comprises a user mouthpiece 158 and filter tube 140, if there are anybyproducts created during operation they will remain in the disposableconsumable-containing package 102, which is changed out when the userinserts a new consumable-containing package 102, and filter tube 140 ifnecessary, into the case 202. Thus, the interior of case 202 stays cleanduring operation.

In the preferred embodiment, the top 222 of the case 202 comprises auser interface 230. Placing the user interface 230 at the top 222 of thecase 202 allows the user to easily check the status of the device 100prior to use. The user could potentially view the user interface 230even while inhaling. The user interface 230 may be multi-color LED (RGB)display for device status indication during use. A light-pipe may beused to provide wide angle visibility of this display. By way of exampleonly, user interface 230 has a 0.96 inch (diagonal) OLED display with128×32 format and I2C (or SPI) interface. The user interface 230 iscapable of haptic feedback 234 (vibration) and audio feedback 250(piezo-electric transducer). In some embodiments, a clear plastic (PC orABS) cover may be placed over the OLED glass to protect it fromdamage/scratches.

The back 212 of the case comprises a trigger 232, which is a fingeractivated (squeeze) button to turn the device on/initiate “puff.”Preferably, the trigger 232 is adjacent to the top 212. In thisconfiguration, the user can hold the case 202 as intended with his orher index finger on or near the trigger 232 for convenient actuation. Insome embodiments, a locking mechanism may be provided on the trigger232—either mechanically or through electrical interlock that requiresthe case 202 to be opened before the trigger 232 is electricallyenabled. In some embodiments, a haptic feedback motor 234 may bemechanically coupled to the trigger 232 to improve recognition of hapticfeedback by the user during operation. Actuation of the trigger 232powers the induction heating element 160 to heat the susceptor 106.

The device 100 is powered by a battery 220. Preferably, the battery 220is a dual cell Li-ion battery pack (series connected) with 4 Acontinuous draw capability, and 650-750 mAh rated. The dual cell packmay include protection circuit. The battery 220 can be charged with aUSB Type “C” connector 236. The USB type “C” connector 236 can also beused for communications. The controller 166 may also provide for batteryvoltage monitoring 238 for battery state of charge/discharge display.

The trigger 232 is operatively connected to the induction coil driver244 via the controller 166. The induction coil driver 240 activates theinductive heating element 160 to heat the susceptor 106. The presentinvention eliminates the motor driven coil design in the prior art. Theinduction coil driver 240 can provide drive/multiplexing for multiplecoils. For example, the induction coil driver 240 may providedrive/multiplexing for 6 or more coils. Each coil is wrapped around onesegment of the consumable-containing package 102 and can be actuated atleast one or more times. Therefore, one segment of theconsumable-containing package 102 can be heated twice, for example. In adevice 100 having six coils, the user could extract 12 “puffs” from thedevice 100.

The induction coil drive circuit in the preferred embodiment may bedirectly controlled by a microprocessor controller 166. A specialperipheral in this processor (Numerically Controlled Oscillator) allowsit to generate the frequency drive waveforms with minimal CPU processingoverhead. The induction circuit nay have one or more parallel connectedcapacitors, making it a parallel resonant circuit.

The drive circuit may include current monitoring with a “peak detector”that feeds back to an analog input on the processor. The function of thepeak detector is to capture the maximum current value for any voltagecycle of the drive circuit providing a stable output voltage forconversion by an analog-to-digital converter (part of the microprocessorchip) and then used in the induction coil drive algorithm.

The induction coil drive algorithm is implemented in firmware running onthe microprocessor. The resonant frequency of the induction coil andcapacitors will be known with reasonable accuracy by design as follows:

Frequency of resonance (in Hertz)=1/(2*pi*SQRT{L*C})

where: pi=3.1415 . . . ,

SQRT indicates the square root of the contents in the brackets {. . . },

L=the measured inductance of the induction coil, and

C=the known capacitance of the parallel connected capacitors.

There will be manufacturing tolerances to the values of L and C (fromabove), which will produce some variation in the actual resonantfrequency versus that which is calculated using the formula above.Additionally, there will be variation in the inductance of the inductioncoil based on what is located inside of this coil. In particular, thepresence of a ferrous metal inside (or in the immediate vicinity) ofthis coil will result in some amount of inductance change resulting in asmall change in the resonant frequency of the L-C circuit.

The firmware algorithm for driving the induction coil will sweep thefrequency of operation over the maximum expected frequency range, whilesimultaneously monitoring the current, looking for the frequency wherethe current draw is at a minimum. This minimum value will occur at thefrequency of resonance. Once this “center frequency” is found, thealgorithm will continue to sweep the frequency by a small amount oneither side of the center frequency and adjust the value of the centerfrequency as required to maintain the minimum current value.

The electronics are connected to the controller 166. The controller 166allows for a processor based control of frequency to optimize heating ofthe susceptor 106. The relationship between frequency and temperatureseldom correlates in a direct way, owing in large part to the fact thattemperature is the result of frequency, duration and the manner in whichthe consumable-containing package 102 is configured. The controller 166may also provide for current monitoring to determine power delivery, andpeak voltage monitoring across the induction coil to establishresonance. By way of example only, the controller may provide afrequency approximately 400 kHz to approximately 500 kHz, andpreferably, 440 kHz with a three-second pre-heat cycle to bring thetemperature of the susceptor 106 to 400 degrees Celsius or higher in onesecond. In some embodiments, the temperature of the susceptor 106 can beraised to 550 degrees Celsius or higher in one second. In someembodiments, the temperature can be raised as high as 800 degreesCelsius. Thus, the present invention has an effective range of 400-800degrees Celsius. In prior art devices, such temperatures would combustthe consumable, making the prior art devices ineffective at thesetemperatures. In the present invention, such high temperatures can stillbe used to improve the efficiency of aerosol production and allow forquicker heat times.

The device 100 may also comprise a communications system 242. In thepreferred embodiment. Bluetooth low energy radio may be used tocommunicate with a peripheral device. The communications system 242 mayserial interface to the main processor for communicating informationwith a phone, for example. Off-the-shelf RE module (pre-certified: FCC,IC, CE, MIC) can also be used. One example utilizes Laird BL652 modulebecause SmartBasic support allows for rapid application development. Thecommunication system 242 allows the user to program the device 100 tosuit personal preferences related to the aerosol density, the amount offlavor released, and the like by controlling the frequency and the3-stage duty cycle, specifically, the pre-heat stage, heating stage, andwind-down stage of the inductive heating elements 160. The communicationsystem 242 may have one or more USB ports 236.

In some embodiments, an RTC (Real-time Clock/Calender) with batteryback-up may be used to monitor usage information. The RTC can measureand store relevant user data to be used in conjunction with an externalapp downloaded on to a peripheral device, such as a smartphone.

In some embodiments, a micro-USB connector (or USB type C connector orother suitable connector) may be located on the bottom of the case 202.Support connector with plastics may be provided on all sides to reducestress on connector due to cable forces.

By way of example only, the device 100 may be used as follows. Power forthe device may be turned on from momentary actuation of the trigger 232.For example, a short press of the trigger (<1.5 sec) may turn the device100 on but does not initiate the heating cycle. A second short press ofthe trigger 232 (<1 sec) during this time will keep the device 100 onfor a longer period of time and initiate Bluetooth advertising if noactive (bonded) Bluetooth connection with phone currently exists. Alonger press of the trigger 232 (>1.5 sec) initiates the heating cycle.The power for the device 100 may remain on for a short period of timeafter each heating cycle (e.g., 5 sec) to display updated unit status onthe OLED user interface 230 before powering off. In some embodiments,the device 100 may power on when the consumable-containing package 102is deployed from the case 202. In some embodiments, a separate powerswitch 246 may be used to turn the device on and off.

When an active connection is found with a smartphone and the customapplication is running on the smartphone, then the device 100 willremain powered on for up to 2 minutes before powering off. When thebattery level is too low to operate, the user interface display 230flashes several times (showing battery icon at “0%” level) beforeturning unit off.

In some embodiments, the user interface 230 may display a segmentedcigarette showing which segments remain (solid fill) versus whichsegments have been used (dotted outline) as an indicator of how much ofthe consumable-containing package 102 still contains consumable productsto be released. The user interface 230 can also display a battery iconupdated with current battery status, charging icon (lightning bolt) whenthe device is plugged in, and a Bluetooth icon when active connectionexists with a smartphone. The user interface 230 may show the Bluetoothicon flashing slowly when no connection exists but the device 100 isadvertising.

The device may also have an indicator 248 to inform the user of thepower status. The indicator 248 may be an RGB LED. By way of exampleonly, the RGB LED can show a green LED on when the device is firstpowered on, a red LED flashing during the preheat time, a red LED on(solid) during the “inhale” time, and a blue LED flashing duringcharging. Duty cycle of flashing indicates the battery's relative stateof charge (20-100%) in 20% increments (solid blue means fully charged).A fast flashing of blue LED may be presented when an active Bluetoothconnection is detected (phone linked to device and custom app on phoneis running).

Haptic feedback can provide additional information to the user duringuse. For example, 2 short pulses can be signaled immediately when poweris turned on (from finger trigger button). An extended pulse at the endof preheat cycle can be signaled to indicate the devices referinhalation (start of HNB “inhale” cycle). A short pulse can be signaledwhen USB power is first connected or removed. A short pulse can besignaled when an active Bluetooth connection is established with anactive phone app running on the smartphone.

A Bluetooth connection can be initiated after power is turned on from ashort (<1.5 sec) press of the finger grip button. If no “bonded” BLE(Bluetooth Low Energy) connection exists, that the devices may beginslow advertising (“pairing” mode) once a second short press is detectedafter initial short press is detected that powers the device on. Once aconnection is established with the smartphone application, the Bluetoothicon on the user interface display 230 may stop flashing and the blueLED will turn on (solid). If the device 100 is powered on and it has a“bonded” connection with a smartphone, then it may begin advertising toattempt to re-establish this connection with the phone up until itpowers off. If the connection with this smartphone is able to bere-established, then the unit may remain powered on for up to 2 minutesbefore powering itself off. To delete a bonded connection, the user canpower the device on with a short press followed by another short press.While BLE icon is flashing, the user can press and hold the trigger 232until the device 100 vibrates and the Bluetooth icon disappears.

So, by tight control of the afore-mentioned conversion efficiencyfactors and the product consistency factors, it is possible to providecontrolled delivery of heat to the consumable-containing unit 104. Thiscontrolled delivery of heat involves a microprocessor controller 166 forthe monitoring of the induction heating system 160 to maintain variouslevels of electrical poi delivery to the susceptor 106 over controlledintervals of time. These properties enable a user-control feature thatwould allow the selection of certain consumable flavors as determined bythe temperature at which the consumable aerosol is produced.

The foregoing description of the preferred embodiment of the inventionhas been presented for the purposes of illustration and description. Itis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the above teaching. It is intended that the scope of theinvention not be limited by this detailed description, but by the claimsand the equivalents to the claims appended hereto.

What is claimed is:
 1. A device, comprising: a) a consumable-containingunit comprising compressed powder; b) a susceptor embedded within theconsumable-containing unit; c) a paper tube encasing theconsumable-containing unit and the susceptor, the paper tube comprisinga first end and a second end opposite the first end; d) an end cap atthe first end of the paper tube; e) a mouthpiece at the second end ofthe paper tube; f) an inductive heating element configured to heat thesusceptor to temperatures from 550 degrees C. to 800 degrees C.; g) acase configured to contain the consumable-containing unit, thesusceptor, the paper tube, and the inductive heating element; and h) acontroller to control the inductive heating element.
 2. A device,comprising: a) a consumable-containing unit comprising compressedpowder; b) a susceptor embedded within the consumable-containing unit;c) a housing encasing the consumable-containing unit and the susceptor,the housing comprising a first end and a second end opposite the firstend; d) an end cap at the first end of the housing; e) a mouthpiece atthe second end of the housing; and f) an inductive heating element inthe housing, the inductive heating element configured to heat thesusceptor to temperatures from 550 degrees C. to 800 degrees C.
 3. Thedevice of claim 2, wherein the end cap comprises a first filter.
 4. Thedevice of claim 3, wherein the mouthpiece comprises a second filter. 5.The device of claim 4, wherein the consumable-containing unit is a tubeshape.
 6. The device of claim 2, further comprising a case configured tocontain the consumable-containing unit, the susceptor, the housing, andthe inductive heating element.
 7. The device of claim 6, furthercomprising a controller operatively connected to the inductive heatingelement to control the inductive heating element.
 8. A device,comprising: a) a compressed consumable-containing unit comprising acompressed powder; b) a susceptor embedded within the compressedconsumable-containing unit; c) a housing encasing the compressedconsumable-containing unit and the susceptor, the housing comprising afirst end and a second end opposite the first end; and d) an inductiveheating element inside the housing, the inductive heating elementconfigured to heat the susceptor to temperatures from 550 degrees C. to800 degrees C.
 9. The device of claim 8, further comprising an end capat the first end of the housing.
 10. The device of claim 9, wherein theend cap comprises a filter.
 11. The device of claim 8, furthercomprising a mouthpiece at the second end of the housing.
 12. The deviceof claim 11, wherein the mouthpiece comprises a filter.
 13. The deviceof claim 8, further comprising a case to contain theconsumable-containing unit, the susceptor, and the housing.
 14. Thedevice of claim 8, further comprising a controller inside the case andoperatively connected to the inductive heating element.
 15. The deviceof claim 8, wherein the housing is a paper tube.
 16. A method ofmanufacturing a device for generating an inhalable aerosol, the methodcomprising: a) compressing a powder form of a consumable-containing unitaround a susceptor; b) placing the consumable-containing unit and thesusceptor into a housing having a first end and a second end; c) placingan end cap at the first end of the housing; d) placing a mouthpiece atthe second end of the housing e) placing the housing into a case,wherein the case comprises an inductive heating element configured toheat the susceptor to temperatures from 550 degrees C. to 800 degreesC., whereby the device for generating an inhalable aerosol ismanufactured.
 17. The method of claim 16, further comprising providing acontroller configured to control the inductive heating element.